Embolic protection filter having an improved filter frame

ABSTRACT

An embolic protection filter having an improved filter frame and method of making the same. In at least some embodiments, the present invention includes an embolic protection filter coupled to an elongate shaft. The filter may include a filter frame assembly having one or more frame members. The frame members may include a filter mouth defining portion.

FIELD OF THE INVENTION

[0001] The present invention pertains to embolic protection devices. More particularly, the present invention pertains to embolic protection devices having a refined filter frame.

BACKGROUND

[0002] Heart and vascular disease are majors problem in the United States and throughout the world. Conditions such as atherosclerosis result in blood vessels becoming blocked or narrowed. This blockage can result in lack of oxygenation of the heart, which has significant consequences since the heart muscle must be well oxygenated in order to maintain its blood pumping action.

[0003] Occluded, stenotic, or narrowed blood vessels may be treated with a number of relatively non-invasive medical procedures including percutaneous transluminal angioplasty (PTA), percutaneous transluminal coronary angioplasty (PTCA), and atherectomy. Angioplasty techniques typically involve the use of a balloon catheter. The balloon catheter is advanced over a guidewire such that the balloon is positioned adjacent a stenotic lesion. The balloon is then inflated and the restriction of the vessel is opened. During an atherectomy procedure, the stenotic lesion may be mechanically cut away from the blood vessel wall using an atherectomy catheter.

[0004] During angioplasty and atherectomy procedures, embolic debris can be separated from the wall of the blood vessel. If this debris enters the circulatory system, it could block other vascular regions including the neural and pulmonary vasculature. During angioplasty procedures, stenotic debris may also break loose due to manipulation of the blood vessel. Because of this debris, a number of devices, termed embolic protection devices, have been developed to filter out this debris.

BRIEF SUMMARY

[0005] The present invention pertains to refinements to embolic protection filters, frames, and methods of making the same. In some embodiments, an embolic protection filter device includes an elongate shaft having an embolic protection filter coupled thereto. The filter may include a filter frame assembly and a filter material or fabric coupled to the filter assembly.

[0006] In at least some embodiments, the filter frame assembly may include two or more filter member. Each filter member may include a filter mouth defining portion and a shaft engaging portion. Including a plurality of filter members may incorporate a number of desirable features into the filtering device as described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a partial cross-sectional view of an example embolic protection device disposed within a body lumen;

[0008]FIG. 2 is a perspective view of an example embolic protection device;

[0009]FIG. 3 is a flattened view of an example frame member;

[0010]FIG. 4 is a plan view of an example frame member having a filter material coupled thereto;

[0011]FIG. 5 is a cross-sectional view taken through line 5-5 in FIG. 2;

[0012]FIG. 6 is a plan view of a frame member;

[0013]FIG. 7 is a plan view of a frame member that is partially flattened;

[0014]FIG. 8 is a plan view of a frame member that is partially flattened and split;

[0015]FIG. 9 is a flattened view of another example frame member;

[0016]FIG. 10 is a plan view of another example frame member having a filter material coupled thereto;

[0017]FIG. 11 is a perspective view of another example embolic protection device; and

[0018]FIG. 12 is a cross-sectional view taken through line 12-12 in FIG. 11.

DETAILED DESCRIPTION

[0019] The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The detailed description and drawings illustrate example embodiments of the claimed invention.

[0020]FIG. 1 is a partial cross-sectional view of an example embolic protection device 10 disposed within a blood vessel 12 adjacent an intravascular lesion 14. In at least some embodiments, device 10 can be used to filter embolic debris generated, for example, by treatment of lesion 14. Device 10 may include an elongate shaft or guidewire 16 having an embolic protection filter 18 coupled thereto. Device 10 may include a number of refinements that, for example, improve apposition of the walls of blood vessel 12 by filter 18, shorten the landing zone of filter 18, shorten the vessel footprint, as well as other desirable features as described in more detail below.

[0021] Filter 18 may include a filter frame assembly 20 and a filter material or fabric 22 coupled to frame assembly 20. In general, filter 18 may be adapted to operate between a first generally collapsed configuration and a second generally expanded configuration for collecting debris in a body lumen. Filter material 22 can be drilled (for example, formed by known laser techniques) or otherwise manufactured to include at least one opening. The holes or openings can be sized to allow blood flow therethrough but restrict flow of debris or emboli floating in the body lumen or cavity. Frame assembly 20 may be coupled to shaft 14 by a coupling 24. Coupling 24 may be one or more windings of frame assembly about shaft 14 or may be a fitting disposed over an end of frame assembly 20 to attach it to shaft 14.

[0022] Frame assembly 20 may include one or more frame members 26. For example, a perspective view of an example frame assembly 20 having two frame members, indicated by reference numbers 26 a and 26 b, is shown in FIG. 2. It can be appreciated, however, that the precise number of frame members 26 can be altered without departing from the spirit of the invention. For example, it may be desirable to include three or more frame members 26 in alternative example frame assemblies.

[0023] Each of the one or more frame members 26 a/b can each be configured to include a mouth defining portion, indicated by reference numbers 28 a and 28 b, and a shaft engaging portion, indicated by reference numbers 30 a and 30 b and best seen in FIG. 3. The mouth defining portions 28 a/b may be arranged to define an opening or mouth 29 of filter 18. In some embodiments, mouth defining portions 28 a/b form a portion of a generally circular filter mouth 29. For example, the two mouth defining portions 28 a/b shown in FIG. 2 each span about 180° or are each roughly a semi-circular portion of a circular filter mouth 29. It can be appreciated that the shape of filter mouth 29 can vary without departing from the spirit of the invention. For example, filter mouth 29 may be oval, irregular, polygonal, or any other suitable shape. Moreover, the relative proportion of filter mouth 29 that each mouth defining portion 28 a/b spans can also vary. For example each mouth defining portion 28 a/b may span an equal proportion or each may span differing proportions.

[0024] Mouth defining portions 28 a/b may be skewed or angled in the proximal or distal direction relative to the longitudinal axis of shaft 14. For example, mouth defining portions 28 a/b may each include a proximal end 32 a/b and a distal end 34 a/b, and portions 28 a/b may be skewed so that distal ends 34 a/b are positioned distally along the longitudinal axis of shaft 14 relative to proximal ends 32 a/b. This structural feature may result in a number of desirable features as described below. In some embodiments, distal ends 34 a/b may include a slight curve or bend, which may decrease or otherwise blunt any sharpness that may be associated with distal ends 34 a/b. Alternatively, distal ends 34 a/b may include other modifications such as a solder or weld ball, a radiused or rounded end, and the like.

[0025] Shaft engaging portions 30 a/b generally are the regions of frame assembly 20 where frame members 26 a/b are coupled to shaft 16, for example by coupling 24. In general, shaft engaging portions 30 a/b can be disposed adjacent shaft 16 so as to at least partially secure filter 18 to shaft 16. The exact attachment means can vary and is not necessarily limited to coupling 24. For example, shaft engaging portions 30 a/b may be coupled to shaft by a mechanical bond such as a crimp, by adhesives, by thermal bond such as a weld, and the like.

[0026] As suggested above, the above features of device 10 may enhance the apposition of the walls of vessel 12 and/or the compliance to the vessel walls. It can be appreciated that the greater the wall apposition achieved by filter 18, the less likely it is that embolic debris will be able float past filter 18 at locations where filter 18 is spaced from the vessel wall. In at least some embodiments, the inclusion of a plurality frame members 26 a/b allows frame assembly 20 to be more compliant to the vessel wall. More particularly, because mouth defining portions 28 a/b of frame members 26 a/b each define a portion of filter mouth 29 (e.g., each defining about 180° of a circular filter mouth 29), irregularities in the shape of the vessel wall can be “absorbed” by one frame member without having a major effect on the shape of the other. For example, a blood vessel having an inward projecting stenosis adjacent filter 18 could cause one of the mouth defining portions (e.g., portion 28 a) to be partially displaced by the irregular or non-circular cross-sectional shape at the stenosis. However, because the remainder of the vessel may have a different, generally circular cross-sectional shape, the other mouth defining portion (e.g., portion 28 b) can remain essentially apposed, independently of portion 28 a. Thus, the overall wall apposition realized by device 10 may be enhanced relative to other filter types. Additionally, it may be desirable to add additional frame members, which may add to this feature.

[0027] In some embodiments, frame assembly 20 (including the individual components thereof) can be made of any suitable materials including metals, metal alloys, polymers, or the like, or combinations or mixtures thereof. Some examples of suitable metals and metal alloys include stainless steel, such as 304v stainless steel; nickel-titanium alloy, such as nitinol, nickel-chromium alloy, nickel-chromium-iron alloy, cobalt alloy, or the like; or other suitable material. The word nitinol was coined by a group of researchers at the United States Naval Ordinance Laboratory (NOL) who were the first to observe the shape memory behavior of this material. The word nitinol is an acronym including the chemical symbol for nickel (Ni), the chemical symbol for titanium (Ti), and an acronym identifying the Naval Ordinance Laboratory (NOL).

[0028] Additionally, frame assembly 20 can be configured from a number of structurally different members. For example, frame assembly 20 can be manufactured from wires, ribbons, tubes, and the like. These structures may have a generally round cross-sectional area, be flattened, be irregular in shape, etc. The used of wires or other “pre-assembled” structures may also help to decrease manufacturing cost by obviating the need to laser cut or otherwise process components of frame assembly 20.

[0029] Shaft 16 may also be comprised of materials similar to those listed above. In at least some embodiments shaft 16 can be a guidewire. It can be appreciated, however, that shaft 16 could also be essentially any medical device. For example, shaft 16 may comprise a catheter (e.g., therapeutic, diagnostic, or guide catheter), a tubular filter cartridge configured to be slidable over a guidewire or catheter, an endoscopic device, a laproscopic device, or any other suitable device.

[0030] The construction of device 10 may include steps generally illustrated in FIGS. 3 and 4. For example, FIG. 3 depicts a flat view of an example set of frame members 26 a/b. Frame members 26 a/b can be adapted and configured for the manufacture of filter 18 having the desired dimensions for the appropriate invention. For example, the lengths of members 26 a/b can be varied relative to the circumference of the target site in a blood vessel (πD_(v), where D_(v) is the diameter of the blood vessel adjacent the target site) so that the size of filter mouth 29 approximates the circumference or size along the inside of the vessel wall. This feature allows filter 18 to have improved 360° apposition to the inside wall of the vessel.

[0031] Frame members 26 a/b can be disposed over a mandrel (not shown) to bend them into the appropriate shape. For example, shaft defining portions 30 a/b can be bent into a configuration appropriate for attaching them to shaft 16. Additionally, in at least some embodiments frame members 26 a/b can be bent adjacent filter mouth defining portions 28 a/b so that these regions are generally semi-circular. It can be appreciated that the invention should not be limited to only this particular shape and, in general, filter mouth defining portions 28 a/b are configured to occupy as much of vessel circumference as desired. For example, the cross-sectional shape of the target site in the vessel may be slightly oval in shape or otherwise differ from being circular. Accordingly, the shape of mouth defining portions 28 a/b can be varied to approximate these shapes and, thus, better achieve 360° wall apposition. As stated above, the relative proportions that each of the filter mouth defining portions 28 a/b span can also vary.

[0032] At some point in the manufacturing process it may be desirable to couple or attach filter material 22 to frame assembly 20. For example, filter material 22 can be coupled to frame assembly 20 at mouth defining portions 28 a/b as shown in FIG. 4. A number of different attachment mechanisms may be used to couple mouth defining portions 28 a/b and filter material 22. Some suitable attachment mechanism may include adhesive bonding, thermal bonding, and the like.

[0033] As stated above, mouth defining portions 28 a/b may be skewed or angled relative to the longitudinal axis of shaft 16. This skew angle θ can be seen in the flat view of FIG. 4 as a mouth defining portions 28 a/b being slanted or angled. Skew angle θ of mouth defining portions 28 a/b can be equal to each other as shown or may be different. The inclusion of skew angle θ can give filter 18 a number of desirable features. For example, if proximal ends 32 a/b of mouth defining portions 28 a/b are aligned, a vessel footprint length L_(f) is defined that is proportional to angle θ. The footprint length L_(f) is understood to be the length of filter 18 that can be in direct contact with the inside wall of the vessel. It can be appreciated that in at least some embodiments, regions of filter 18 that are distal of L_(f) may be conical in shape and, thus, taper away from the vessel wall.

[0034] Because of skew angle θ, frame members 26 a/b may be generally parallel to one another. According to these embodiments, one or more relatively short, bridging regions 36 a/b of filter material 22 may be disposed between frame members 26 a/b. It can be appreciated that the length of bridging regions 36 a/b are about equal to each other and to footprint length L_(f). In some other embodiments, the skew angle θ of each frame member 26 a/b may be different and, thus, the lengths of bridging regions 36 a/b may have different lengths. Bridging regions 36 a/b can also prevent gaps from being present between frame members 26 a/b, which can maintain the integrity of the vessel wall apposition.

[0035] As stated above, footprint length L_(f) and skew angle θ are generally proportional to one another. More particularly, as angle θ becomes larger, footprint length L_(f) becomes longer. Thus, a number of variations of angle θ and footprint length L_(f) can be utilized in different embodiments of the invention. For example, it may be desirable due to the physiology or anatomy of the treatment site, for footprint length L_(f) of filter 18 to be relatively short. According to this embodiment, manufacturing of filter 18 can include filter members 26 a/b being skewed a relatively small skew angle θ.

[0036] Footprint length L_(f) can also be related to the size the landing zone of the filter. The footprint length L_(f) is understood to be the longitudinal length of filter 18 that is designed to be in contact with the vessel wall when filter 18 is deployed in the vessel. Landing zone is generally understood to be the overall longitudinal length of the filter. Thus, in embodiments where the footprint length L_(f) is decreased, the landing zone can also be decreased. Having a short landing zone can advantageously permit filter 18 to be used at intravascular locations that are relatively short and would otherwise be inaccessible to traditional filters. For example, the length of a portion of the renal artery between the abdominal aorta and the kidney is relatively short. Diagnosis or other interventions at the junction of the renal artery and the kidney would not easily be accomplished by using conically shaped filter because the filter may extend into the kidney, possibly causing damage to the kidney. Thus, example embodiments of filter 18 having a generally short landing zone make this location more accessible for filtering. A number of additional intravascular locations may similarly benefit from example filters 18 having a shortened landing zone.

[0037] At the desired time in the manufacturing process, frame assembly 20 can be formed into the appropriate shape to define filter 18 (please see FIG. 2). A cross-sectional view taken through line 5-5 of FIG. 2 is shown in FIG. 5. From FIG. 5 it can be seen that each mouth defining portion 28 a/b can be configured to span about 180°.

[0038] As stated above, however, the relative proportion that each portion 28 a/b can be varied as well as the number of mouth defining portions. For example, frame assembly 20 may include three mouth defining portions and each may span about 120°.

[0039] Frame members 26 a/b can be shafts having a relatively constant outside diameter D_(w) as shown in FIG. 6. According to this embodiment, a generic frame member 26 can be configured to have the desired shape, for example the shape depicted in FIG. 3. Alternatively, frame member 26 may be include a non-flattened portion 38 and a flattened portion 40 as shown in FIG. 7. Flattened portion 40 of frame member 26 may have a flattened thickness F_(T) and a flattened cross-sectional length F_(L), both of which may vary in alternative embodiments of the invention. A tapered portion 42 may be disposed between non-flatted portion 38 and flattened portion 40. It should be noted that in alternative embodiments, frame member 26 may comprise a generally flat or rectangular ribbon, which would include any desirable features of flattened portion 40.

[0040] In at least some embodiments, flattened portion 40 may be disposed adjacent the filter mouth defining regions 28 a/b. Because of the attenuated F_(T), disposing flattened portion 40 adjacent filter mouth defining regions 28 a/b can reduce the crossing profile diameter of filter 18. This feature may be desirable, for example during interventions within small or sensitive blood vessels.

[0041]FIG. 8 illustrates an alternative example frame member 126. Frame member 126 is essentially the same as frame member 26 except that it flattened portion 140 is cut to define two flattened portions 140/140′. Frame member 126 may also include a tapered region 142. It can be appreciated that variations to the length of the taper LT (i.e., the length of frame member 126 adjacent taper 142), the length of flattened portion LF, thickness of the cut CT, and length of the cut region LC of frame member 126 are within the scope of the invention.

[0042] One or more of frame members 126 may be used to manufacture an alternative example filter. For example, FIG. 9 illustrates a flattened view of frame members 126 a/b configured in a fashion that is essentially analogous to the flattened view shown in FIG. 3. According to this embodiment, each frame member 126 a/b includes a multi-leg filter mouth defining portion 128 a/a′ and 128/b/b′. It can be seen in FIG. 9 that the legs are at least partially curved. The amount of or sharpness of the curve can be altered to vary the footprint length L_(F), similar to how skew angle θ can be varied in the above discussion. Similar to what is described above, filter material 22 can be coupled to frame members 126 a/b as shown in FIG. 10.

[0043] At the desired time in the manufacturing process, filter members 126 a/b can be formed into the appropriate shape to define a filter 118 as illustrated in FIG. 11. The resultant filter 118 is essentially the same in form and function as filter 18 except that frame members 126 a/b include multi-leg mouth defining portions 128 a/a′ and 128 b/b′ as described above. A cross-sectional view of filter 118 that is taken through line 12-12 is shown in FIG. 12.

[0044] It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed. 

What is claimed is:
 1. An embolic protection filter assembly, comprising: a first frame member having a first shaft-engaging portion and a first mouth portion; a second frame member having a second shaft-engaging portion and a second mouth portion; wherein the first mouth portion and the second mouth portion define a filter mouth; a filter material coupled to the first and second frame members adjacent the first and second mouth portions; and an elongate shaft coupled to the first and second shaft-engaging portions and extending through the filter.
 2. The assembly of claim 1, wherein the shaft comprises a guidewire.
 3. The assembly of claim 1, wherein the shaft comprises a tube adapted and configured for being slidably disposed over an elongate wire.
 4. The assembly of claim 1, wherein the filter mouth has a generally circular shape spanning 360 degrees.
 5. The assembly of claim 4, wherein each of the first and second filter mouth portions includes one or more legs configured to span about 180 degrees of the filter mouth.
 6. The assembly of claim 4, wherein the first and second filter mouth portions each span different proportions of the filter mouth.
 7. The assembly of claim 4, further comprising a third frame member having a third shaft-engaging portion and a third mouth portion.
 8. The assembly of claim 7, wherein each of first, second, and third mouth portions include one or more legs configured to span about 120 degrees of the filter mouth.
 9. The assembly of claim 7, wherein the first, second, and third filter mouth portions span different proportions of the filter mouth.
 10. The assembly of claim 1, wherein the shaft has a longitudinal axis and wherein the first mouth portion is oriented perpendicularly to the longitudinal axis.
 11. The assembly of claim 1, wherein the shaft has a longitudinal axis and wherein the first mouth portion is skewed at an angle relative to an axis pointed perpendicularly to the longitudinal axis.
 12. The assembly of claim 11, wherein the angle is acute relative to the axis pointed perpendicularly to the longitudinal axis.
 13. The assembly of claim 1, wherein the first and second mouth portions are connected by a bridging portion of the filter material disposed between the mouth portions.
 14. The assembly of claim 1, wherein the first frame member includes a circular region having a generally circular cross-sectional shape and a flattened region having a generally oval cross-sectional shape.
 15. The assembly of claim 14, wherein the flattened region is disposed adjacent the first filter mouth portion.
 16. The assembly of claim 14, wherein the flattened portion is split to include a first leg and a second leg.
 17. An embolic protection filter assembly, comprising: a first frame member having a first shaft-engaging portion and a first mouth portion, the first mouth portion include a proximal end and a distal end; a second frame member having a second shaft-engaging portion and a second mouth portion, the first mouth portion include a proximal end and a distal end; wherein the first mouth portion and the second mouth portion define a filter mouth; a filter material coupled to the first and second frame members; wherein a filtering portion of the filter material is coupled to and extends distally from the first and second mouth portions; a first bridging portion of the filter material extending between the proximal end of the first mouth portion and the distal end of the second mouth portion; a second bridging portion of the filter material extending between the proximal end of the second mouth portion and the distal end of the first mouth portion; and an elongate shaft coupled to the first and second shaft-engaging portions.
 18. The assembly of claim 17, wherein the shaft comprises a guidewire.
 19. The assembly of claim 17, wherein the shaft comprises a tube adapted and configured for being slidably disposed over an elongate wire.
 20. The assembly of claim 17, wherein the filter mouth has a generally circular shape.
 21. The assembly of claim 20, wherein the first and second filter mouth portions each span different proportions of the filter mouth.
 22. The assembly of claim 20, wherein each of the first and second filter mouth portions includes one or more legs and are each have a semicircular shape.
 23. The assembly of claim 22, wherein the semicircular shapes of the first and second filter mouth portions are skewed relative to one another.
 24. The assembly of claim 17, wherein the shaft has a longitudinal axis and wherein the first mouth and second mouth portions are oriented perpendicularly to the longitudinal axis.
 25. The assembly of claim 17, wherein the shaft has a longitudinal axis and wherein the first and second mouths portions are skewed at an angle relative to an axis pointed perpendicularly to the longitudinal axis.
 26. The assembly of claim 25, wherein the angle is acute relative to the axis pointed perpendicularly to the longitudinal axis.
 27. The assembly of claim 17, wherein the first frame member includes a circular region having a generally circular cross-sectional shape and a flattened region having a generally oval cross-sectional shape.
 28. The assembly of claim 27, wherein the flattened region is disposed adjacent the first filter mouth portion.
 29. The assembly of claim 27, wherein the flattened portion is split to include a first leg and a second leg.
 30. An embolic protection filter assembly, comprising: an elongate shaft having a longitudinal axis and a perpendicular axis; a first frame member having a first shaft-engaging portion coupled to the shaft and a first semi-circular portion, the first semi-circular portion being semi-circular in shape and including a proximal end and a distal end; a second frame member having a second shaft-engaging portion coupled to the shaft and a second semi-circular portion, the second semi-circular portion being semi-circular in shape and including a proximal end and a distal end; wherein the first and second semi-circular portions are skewed at an angle relative to the perpendicular axis; a filter material coupled to the first and second frame members; a filtering portion of the filter material coupled to and extends distally from the first and second semi-circular portions; a first bridging portion of the filter material extending between the proximal end of the first semi-circular portion and the distal end of the semi-circular mouth portion; and a second bridging portion of the filter material extending between the proximal end of the second semi-circular portion and the distal end of the first semi-circular portion.
 31. The assembly of claim 30, wherein the shaft comprises a guidewire.
 32. The assembly of claim 30, wherein the shaft comprises a tube adapted and configured for being slidably disposed over an elongate wire.
 33. The assembly of claim 30, wherein each of the first and second semi-circular portions includes one or more legs.
 34. The assembly of claim 30, wherein the first and second frame members each includes a circular region having a generally circular cross-sectional shape and a flattened region having a generally oval cross-sectional shape.
 35. The assembly of claim 34, wherein the flattened regions are disposed adjacent the first and second semi-circular portions.
 36. The assembly of claim 34, wherein at least one of the flattened portions is split to include a first leg and a second leg. 